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automatedassemblysystems-200413091052.pdf
- 2. Automated Assembly Systems 1. Fundamentals of Automated Assembly Systems 2. Quantitative Analysis of Assembly Systems SEcTiOn S
- 3. Automated Assembly - Defined The use of mechanized and automated devices to perform the various assembly tasks in an assembly line or cell Most automated assembly systems are designed to perform a fixed sequence of assembly steps on a specific product that is produced in very large quantities Automated Assembly Systems
- 4. Automated Assembly - Application Characteristics Where is automated assembly appropriate: High product demand Stable product design The assembly consists of no more than a limited number of components The product is designed for automated assembly Automated Assembly Systems
- 5. Advantages Of Automated Assembly Automated Assembly Systems High production rate High product quality and precision Low cost of production Not create the risk to the operator
- 6. Typical Products Alarm clocks Door mechanisms Gear boxes Ball bearings Small electric motors Automated Assembly Systems
- 7. Assembly Processes in Automated Assembly Adhesive bonding Insertion of components Placement of components Riveting Screw fastening Snap fitting Soldering Spot welding Stapling Stitching Automated Assembly Systems
- 8. System Configurations 1. In-line assembly machine 2. Dial indexing machine 3. Carousel assembly system 4. Single-station assembly cell Automated Assembly Systems
- 9. In-Line Assembly Machine A series of automatic workstations located along and in-line transfer system Automated Assembly Systems
- 10. Dial Indexing Machine Base parts are loaded onto fixtures or nests attached to a circular dial table, and components are added at workstations located around the periphery of the dial as it indexes from station to station Automated Assembly Systems
- 11. Dial Indexing Machine Automated Assembly Systems
- 12. Carousel Assembly System A hybrid between circular work flow of dial indexing machine and straight work flow of in-line system Automated Assembly Systems
- 13. Single-Station Assembly Cell Assembly operations are performed on a base part at a single location A robot is sometimes used as the assembly machine Automated Assembly Systems
- 14. Multi-Station vs Single- Station Multi-station assembly machine or line ◦ Faster cycle rate ◦ High production quantities ◦ More operations possible ◦ More components per assembly Single-station assembly cell ◦ Suited to robotic assembly ◦ Intended for lower production quantities Automated Assembly Systems
- 15. Parts Delivery at Workstations Typical parts delivery system at a workstation consists of the following hardware components: 1. Hopper - container for parts 2. Parts feeder - removes parts from hopper 3. Selector and/or orientor - to assure part is in proper orientation for assembly at workhead 4. Feed track - moves parts to assembly workhead 5. Escapement and placement device - removes parts from feed track and places them at station Automated Assembly Systems
- 16. Parts Delivery System at Station Automated Assembly Systems
- 17. Vibratory Bowl Feeder Most versatile of hopper feeders for small parts Consists of bowl and helical track ◦ Parts are poured into bowl ◦ Helical track moves part from bottom of bowl to outlet Vibration applied by electromagnetic base Oscillation of bowl is constrained so that parts climb upward along helical track Automated Assembly Systems
- 18. Vibratory Bowl Feeder Automated Assembly Systems
- 19. Selector and/or Orientor Purpose to establish the proper orientation of the components for the assembly workhead Selector ◦ Acts as a filter ◦ Only parts in proper orientation are allowed to pass through to feed track Orientor ◦ Allows properly oriented parts to pass ◦ Reorients parts that are not properly oriented Automated Assembly Systems
- 20. Parts Selection and Orientation (a) Selector (b) Orientor Automated Assembly Systems
- 21. Feed Track Moves parts from hopper to assembly workhead Categories: 1. Gravity - hopper and feeder are located at higher elevation than workhead 2. Powered - uses air or vibration to move parts toward workhead Automated Assembly Systems
- 22. Escapement and Placement Devices Escapement device ◦ Removes parts from feed track at time intervals that are consistent with the cycle time of the assembly workhead Placement device ◦ Physically places the parts in the correct location at the assembly workstation Escapement and placement devices are sometimes the same device, sometimes different devices Automated Assembly Systems
- 23. Escapement and Placement Devices (a) Horizontal and (b) vertical devices for placement of parts onto dial- indexing table Automated Assembly Systems
- 24. Escapement and Placement Devices Escapement of rivet-shaped parts actuated by work carriers Automated Assembly Systems
- 25. Escapement and Placement Devices Two types of pick-and-place mechanisms for transferring base parts from feeders to work carriers Automated Assembly Systems
- 26. assembly system performance is limited by the parts delivery system rather than the assembly process technology Component quality has an important effect on system performance - poor quality means oJams at stations that stop the entire assembly system oAssembly of defective components in the product Automated Assembly Systems Quantitative Analysis of Assembly Systems
- 27. As the number of stations increases, uptime efficiency and production rate are adversely affected due to parts quality and station reliability effects The cycle time of a multi-station assembly system is determined by its slowest station By comparison with a multi-station assembly system, a single-station assembly cell with the same number of assembly tasks has a lower production rate but a higher uptime efficiency Automated Assembly Systems Quantitative Analysis of Assembly Systems
- 28. Multi-station assembly systems are appropriate for high production applications and long production runs. By comparison, single-station assembly cells have a longer cycle time and are more appropriate for mid-range quantities An automated station should be substituted for a manual station only if it has the effect of reducing cycle time sufficiently to offset negative effects of lower reliability Automated Assembly Systems Quantitative Analysis of Assembly Systems